Definition of the KPI Return rate
Purpose
This document defines the KPI return rate for suppliers of direct material. The purpose is to
measure our supplier performance of delivering conforming material into our factories.
The KPI measures the amount of nonconformance direct material that we detect in our
factories in relationship to the amount of volume of received direct material. Nonconforming
direct material does not conform to the drawing, specifications and/or agreed upon standards.
Quantities will be reported in the units of measure in which they are purchased. This applies
to production parts / saleable units.
Terminology 1
Supplier
Return
Released
On Transit
Received
Quantity
OK
Stock/Line
Factory
In comming
inspection
Suspected
Checked /
Sorted OK
Reworked
In house, vendor or
3rd party
Sorted NOK
Scrapped
Return
Blocked material
R
E
L
E
A
S
E
D
Reworked
Released
Terminology 2
Received: Direct material that has been registerd in a Husqvarna factory system as received.
Blocked: Direct material that are under evaluation and therefore restricted material. Has a status ”Not available” in the
system.
Checked / Sorted OK: Suspected material that has been sorted and/or confirmed to be ok. Has a status ”Available” in the
system.
Sorted NOK: Suspected material that has been sorted and confirmed to be nonconforming material
Scrapped: Sorted NOK material that the supplier has decided to scrap
Rework: Sorted NOK material that the supplier and Husqvarna has agreed to rework.
Returned: Sorted NOK material that Husqvarna has agreed to return.
Released: Blocked direct material that has been analyzed and placed in any of the catagories, Sorted OK, Scrapped,
Reworked or Returned. The physical parts are no longer in the restricted area.
Calculation
SORTED NOK
Return rate =
1 000 000 *
Received
Method
• When a Husqvarna factory identifies suspected material they should immediately remove the batch of
physical parts, and the parts in the system, into a restricted material area.
• In normal case all sorting of suspected material should be handled by the supplier. The suppliers should be
asked if they want to have the batch delivered back to them or if they want to have it delivered to a 3rd
party sorting company. If there is a critical need to sort the suspected material, it could be done by
Husqvarna.
• If Husqvarna or the suppliers sorts the complete batch at a Husqvarna site – then only the actual
nonconforming parts will have the status ”Sorted NOK”.
• If the supplier takes back the complete batch – then the complete batch will get the status ”Sorted NOK”.
• If the supplier sort at Husqvarna site or sends the batch to a 3rd part sorting company – then only the
actual nonconforming parts will have the status ”Sorted NOK” if the ”Sorted NOK” parts are identified and
available within 10 working days.
Nonconformance vs Conformance
Nonconformance
Conformance
Parts which do not meet drawing specifications or dimensional,
functional, or appearance standards as called out in the
specifications.
Parts that meet all drawing specifications but are not useable .
Out-of-spec parts that require rework/repair in order to be
used.
Parts that meet all specifications and/or standards but have
been claimed by a Husqvarna customer/end user.
Parts damaged from inadequate packaging or transportation
for which the supplier is responsible.
Parts not released and approved for production and/or have no
released drawing (i.e. launch parts, sample/trial parts, DOE
parts, pre-productions parts, etc.).
Parts that are outside the production system will be addressed
through prototype quality measures.
Interim approved PPAP with any defects outside of the
boundaries defined by the deviation.
Parts that have an approved deviation for an out-of-spec
condition cannot be assigned PPM for rejects associated with
the deviated characteristic.
Shipments that are received with mixed parts
Delivery errors,
Parts that are the wrong revision level after the break point has
been established.
Quantity errors ( to few – too many )
Shipments received where the lable on hte box does not match
with the parts inside the box.
This is delivery deviation
How to handle different cases in the systems?
Case
Status in the system
Return rate status
1. A factory places a batch of material in stock.
Available
Received
2 a. A factory places a batch of received material in incoming
inspection area
Blocked – Not available
Received
2 b. Incomming inspection checked the received
Available
Received
3 a. Nonconforming material is identified in stock or at the line.
Batch of material is placed in the area for blocked material.
Blocked – Not available
Received
3 b. Supplier doesn’t want to send the batch to a third party.
Factory sends back the batch to the supplier
Returned
100% Received
4 a. Batch of blocked material is sent to 3rd party for sorting
Blocked – Not available
Received
4 b1. A 3rd party sorted out 70% conformance parts, which
were sent back to the factory, and 30% nonconformance parts
which were scrapped after agreement with the supplier.
70% Available
100% Received
30 % Returned
30 % Returned
4 b2. A 3rd party sorted out 30% nonconforming parts and
reworked the parts to be conforming parts and send them back
to the factory.
100 % Available
100% Received
5. Supplier delivers nonconforming material, but after risk
evaluation a decision is taken to use it anyway.
100 % Available
6. A batch is returned to a supplier as nonconforming material –
supplier proofs it according to specification. We did a mistake the supplier delivered correct material.
Not available
material and found no defects
, 100% Returned
30 % Returned
100% Received
, 100% Returned
Adjust 100% returned to
0% returned for the batch.
Direct material vs Indirect material – packaging material
Direct material
Indirect material
Parts that has a Husqvarna specification/drawing, is part of a
product BOM and are sourced by commodity purchasing.
Material that does not have a Husqvarna specification/drawing
and/or is not part of a product BOM. Material that are
purchased by the local factory organisation.
Example:
Example:
- Labels
- Tape and staples for the packaging box
- Packaging boxes
- Grease or chemicals that are not part of the product BOM
- Grease or chemicals that are part of the product BOM
- Material that are used to support the assambly/packaging
process, but is not part of the product BOM.
- Service parts that are included inside the packaging box